Welding, a critical process in numerous industries, necessitates stringent safety measures, particularly concerning eye protection. The intense light and radiant energy emitted during welding can cause severe eye damage if proper protective gear isn’t used. Welding helmets equipped with appropriate filter lenses, or welding shades, are essential to shield welders’ eyes from harmful UV and IR radiation. This blog delves into the numeric welding shades, their specific applications, and the imperative need to adhere to OSHA and ANSI guidelines.
Numeric Welding Shades: An Overview
Welding shades are numerically rated based on their ability to filter light. These shades range from 2 to 14, with higher numbers indicating greater light filtration. The appropriate shade number is determined by the type of welding process, the material being welded, and the welding current. Selecting the correct shade is crucial for both visibility and protection.
Below is a breakdown of different welding applications with corresponding OSHA minimum and ANSI recommended protective shade number.
| WELDING OPERATION | ARC CURRENT (AMP) |
OSHA MINIMUM PROTECTIVE SHADE NUMBER |
ANSI RECOMMENDED SHADE NUMBER |
| Gas Metal Arc Welding (GMAW) & Flux Cored Arc Welding (FCAW) |
<60 | 7 | – |
| 60-160 | 10 | 11 | |
| 160-250 | 10 | 12 | |
| 250-500 | 10 | 14 | |
| Gas Tungsten Arc Welding (GTAW) | <50 | 8 | 10 |
| 50-150 | 8 | 12 | |
| 150-500 | 10 | 14 | |
| Air Carbon Arc Cutting (CAC-A) (Light) |
<500 | 10 | 12 |
| Air Carbon Arc Cutting (CAC-A) (Heavy) |
500-1000 | 11 | 14 |
| Plasma Arc Welding (PAW) | <20 | 6 | 6-8 |
| 20-100 | 8 | 10 | |
| 1-400 | 10 | 12 | |
| 400-800 | 11 | 14 | |
| Plasma Arc Cutting (PAC) (Light) | <300 | 8 | 9 |
| Plasma Arc Cutting (PAC) (Medium) | 300-400 | 9 | 12 |
| Plasma Arc Cutting (PAC) (Heavy) | 400-800 | 10 | 14 |
| Torch Brazing (TB) | – | 3 | 3 or 4 |
| Torch Soldering (TS) | – | 2 | 2 |
| Carbon Arc Welding (CAW) | – | 14 | 14 |
Applications and Required Welding Shades
- Oxyfuel Gas Welding and Cutting:
- Shade 2-5: Used for light gas welding and cutting operations. Suitable for gas welding on thin materials (up to 1/8 inch) and low-current plasma cutting.
- Shade 6-8: Recommended for medium to heavy gas welding and cutting. As the material thickness and current increase, a darker shade is necessary to protect against the brighter light emitted.
- Gas Metal Arc Welding (GMAW/MIG) and Flux-Cored Arc Welding (FCAW):
- Shade 10: Suitable for low-current (up to 100 amps) MIG welding on thin materials.
- Shade 11: Recommended for moderate-current MIG welding (100-175 amps), providing ample protection while maintaining visibility.
- Shade 12-14: Necessary for high-current MIG welding (175-300 amps), ensuring optimal protection against intense arc light.
- Gas Tungsten Arc Welding (GTAW/TIG):
- Shade 10-14: Depending on the welding current and material thickness, shades 10 to 12 are used for TIG welding. Lower currents and thinner materials require lighter shades, while higher currents and thicker materials necessitate darker shades.
- Shielded Metal Arc Welding (SMAW/Stick Welding):
- Shade 10: Adequate for low-current SMAW (up to 75 amps).
- Shade 11: Suitable for moderate-current SMAW (75-200 amps).
- Shade 12-14: Required for high-current SMAW (200-400 amps) to protect against the intense arc produced.
- Plasma Arc Cutting:
- Shade 8-9: Used for low to moderate current plasma arc cutting.
- Shade 10-14: Necessary for high-current plasma arc cutting, offering protection against the intense plasma arc light.
Importance of Adhering to OSHA and ANSI Guidelines
The Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI) provide comprehensive guidelines to ensure the safety of welders. OSHA mandates the use of appropriate eye protection under its standard 29 CFR 1910.252, which specifies the use of filter lenses with the correct shade number for various welding activities. The ANSI Z87.1 standard outlines the specifications for eye and face protection devices, including welding helmets and goggles, to safeguard against impacts, optical radiation, and other hazards.
Adhering to these guidelines is not only a regulatory requirement but also a critical measure to prevent eye injuries such as photokeratitis (welder’s flash), cataracts, and retinal burns. Employers and safety professionals must ensure that welders are equipped with helmets featuring the correct shade for their specific welding tasks.
Understanding and utilizing the correct welding shades is critical in protecting welders’ eyes from harmful radiation. By following OSHA and ANSI guidelines, welders and safety professionals can significantly reduce the risk of eye injuries, ensuring a safer working environment. Proper training on the selection and use of welding helmets with appropriate filter lenses is essential to not just the welding operation, but also in driving a culture of safety and awareness in the industry.
USA-Made Welding PPE by Paulson Manufacturing
Paulson is known throughout the industry for our innovation and expertise in materials science, optics, and compliance with national & international safety standards. Striking a balance between protection and visibility, our polycarbonate welding face shields and goggles feature a nanoparticle formulation for superior absorption of infrared light & heat. Welders across the country trust our shaded lenses for their quality construction, ergonomic design, and above all, the consistent level of protection they provide.
For more information on the different welding shades and which applications they apply to, please contact us today.
